|Project by Woodster73||posted 09-25-2016 04:15 AM||569 views||1 time favorited||1 comment|
This is a rolling cart with a flip top I built to try to maximize some shop space (I’m just in process of putting a 1-stall garage shop together). I looked at several designs and decided on a slightly beefed up version of one I saw online, I’ll try to find the link to where I saw the design. The carcase is built from 7-ply plywood, the flip top is plywood with cedar spacers. I used cedar mostly because I had some extra laying around, and because I love the way it smells while working it!
I started by cutting most of the plywood for the carcase and top. I don’t have a jointer, so I used my “Big Bertha” jointer plane to plane the Cedar flat on one face and one edge, then used the planer and tablesaw to square the other face and edge. I relieved all the edges with a block plane, then glued up the base and sides, and drilled the holes for the casters. Next, I drilled the holes for the metal pipe I used for the axle in the top.
I then realized I hadn’t cut the slots in the sides that receive the bolts from the top, which turned a really easy pre assembly cut into a pain. I ended up building a little jig and using the router to cut the slots in the sides, as they really need to be in alignment with the center of rotation for the top.
The top is constructed with plywood separated by a cedar frame with the metal rod sandwiched very tightly between them. You can see in the photos how it is constructed, and I used glue and screw construction throughout for stability. I then assembled the top into the carcase using fender washers, which required a fair amount of slight adjusting to fit. I drilled holes through the rod to accommodate large pins. The edge bolts have a bolt recessed into the top with an eye bolt attached to the top bolt. I assembled the whole thing, then flipped it over about a hundred times :).
I mounted the planer and the other two tools with lag bolts that go all the way through to the opposite side plywood for strength. I mounted the planer across the top so I didn’t have to remove the adjustment handle when I flipped it over. I rolled it around the shop for a few days, and the next weekend built the drawer for the bottom. I put a light coat of spray lacquer to protect it a bit.
I made my fair share of mistakes and definitely learned some lessons in the construction, but overall I like the cart. So far it’s rock solid, even with the quite heavy planer mounted. It rolls easily and flips with one hand. Thanks for checking it out!